Multiple component pre-former

ABSTRACT

A multiple component pre-former permits the cutting and preforming of the component axial leads in multiples during a single machine cycle. The ends of the components are secured by tape. A feed system engages the taped ends of the component to advance groups of taped components into position on a die set where the multiple components within the group are cut and formed. Safety switching means are provided which prevent operation of the preformer during periods of loading or unloading of the pre-former. Means are provided to collect all of the cut and formed components.

TJnite ttes atent [19] Parks Mar. 25, 11975 1 MULTTPLE COMPONENT FIRE-FORMER [75] Inventor: William E. Parks, Huntsville, Ala.

[73] Assignee: Avco Corporation, Huntsville, Ala.

[22] Filed: Mar. 4, 1974 [21] Appl. No.: 447,747

[52] US. Cl 140/105, 72/37, 72/DIG. 10

[51] int. Cl BZli 11/00 [58] Field oi Search 140/1, 105; 29/203; 72/DIG. 10, 37

[56] References Cited UNITED STATES PATENTS 3,193,171 7/1965 Johnson et a1 140/105 3,387,474 6/1968 Shoemaker et a1. 72/38 3.738398 6/1973 Galloway 140/105 3,769,823 11/1973 Greeninger 29/203 Golub 140/105 Primary ExaminerLowell A. Larson Attorney, Agent, or Firm-Charles M. Hogan; Eugene C. Goodale; lrwin P. Garfinkle [57] ABSTRACT A multiple component pre-former permits the cutting and pre-forming of the component axial leads in multiples during a single machine cycle. The ends of the components are secured by tape. A feed system engages the taped ends of the component to advance groups of taped components into position on a die set where the multiple components within the group are cut and formed. Safety switching means are provided which prevent operation of the pre-former during periods of loading or unloading of the pre-former. Means are provided to collect all of the cut and formed components.

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MULTIPLE COMPONENT PRE-FORMER BACKGROUND OF THE INVENTION This invention relates generally to cutting and forming operations and more particularly to a machine which will provide an accurate and reliable means for forming axial leaded electronic components.

Prior to installation into electronic assemblies, most electronic components with axial leads, i.e., such as re sistors, diodes, capacitors, etc., require that the leads be cut and formed. In the past, such components have been cut and formed by hand. However, this is a timeconsuming operation and not economically feasible to meet mass production requirements. Equipment has been developed to cut and pre-form such components at a faster rate than can be done by hand. However, such present equipment only processes components individually. Handling by these machines is highly dependent upon the accuracy of the pitch spacings between components to be processed. As an example, quite often the feed mechanism is a pair of wheels having notches formed about the periphery such that the notches will engage the lead of the component and sequentially move one component at a time into the cutting position. If the pitch spacings between the components vary or the components themselves are not parallel, quite often the component will be fed improperly into the cutting position. When this occurs, the integrity of the component may be altered because of shock loads induced upon it or the component and leads may be physically destroyed. Both of these conditions can be very costly, not only in terms of material waste but also in quality assurance.

Accordingly, it is an object of this invention to permit the cutting and pre-forming of multiple components during a single machine cycle.

A further object of this invention is to provide a means for advancing a group of componentsinto the cutting and forming position regardless of the relative pitch between the'respective components.

A still further object of this invention is to provide a multiple component pro-former for processing lead taped components at high volume rates without a decrease in quality assurance.

And yet another object of this invention is to provide a multiple component pre-former which is of simple and economical construction, is easy to operate, and provides formed components at high volume rates with no degradation in quality assurance.

And still a further object of this invention is to provide a multiple component pre-former having sufficient safety features which will prevent operation of the preformer in an unsafe condition such as when the preformer is being loaded.

SUMMARY OF THE INVENTION Other objects, details, uses and advantages of this invention will become apparent as the following description of the exemplary embodiments thereof presented in the accompanying drawings proceeds.

BRIEF DESCRIPTION OF THE DRAWINGS The accompanying drawings show a present exemplary embodiment of this invention in which:

FIG. 1 is a perspective view ofan exemplary embodiment of this invention;

FIG. 2 is an enlarged fragmentary view of the die set in the open position;

FIG. 3 is a diagrammatic representation of the front elevational view of the pre-former of FIG. 1;

FIG. 4 is an end view ofthe take-up reel of FIG. 3;

FIG. 5 is a cross-sectional view of the die set in the open position;

FIG. 6 is a sectional view of the: die set shown in the closed position with the component in position after the cutting and forming operation;

FIG. 7 is a top view of the die block; and

FIG. 8 is the bottom view of the punch plate.

DESCRIPTION OF ILLUSTRATED EMBODIMENT Reference is now made to FIG. 1 of the drawings which illustrates one exemplary embodiment ofthe improved component pre-former apparatus of this invention, which is designated generally by the reference numeral 10. The apparatus 10 is comprised generally of a supply station 12, a component cut and form station 14 and a take-up station 16. The apparatus 10 of this embodiment may be mounted on any suitable bench, frame, or the like 18. Power for the cutting and forming action may be supplied from any suitable means, such as any commercially available pneumatic press or the like 20. Suitable pneumatic and electrical circuitry controls the operation of the press 20, such circuitry being common to the particular press in use and forms no part of the present invention, except as specifically described below.

The press is secured to a support plate 22 in a known manner. The plate 22 is supported above the base plate 24 by a plurality of support posts or rods 26.

As seen in FIG. 2, the cutting and forming station 14 is comprised of a cutting and forming member 28 and a complementally formed component holder 30. In this embodiment, the cutting and forming member 28 is a punch plate and the component holder is a die block, the two members forming a die set.

The punch plate 28 and die block 30 are respectively secured by suitable means to support plates 32 and 34. The support plate 32 is connected in a known manner with the press 20 such that when the press 20 is actuated the punch plate 28 is driven into cooperative engagement with the die block 30.

A supply of components having axial leads, such as, for example, resistor 36, is provided at the supply station 12 as seen in FIGS. 1-3. The components 36 are formed with a continuous tape 38 secured to each end of the component leads. The taped components are mounted on a rotatable reel 40 such that the taped components may be pulled therefrom. The take-up reel 40 is mounted for rotatable movement by any suitable support frame or the like 42 extending from the frame 18.

The taped components 36 are fed over a positioning bar 44 such that the components may be fed in a substantially horizontal position to the cutting and forming stage 14. Guide elements 46 and 48, as seen in FIGS. 2 and 5, are adjustably mounted to the support plate 34 by any suitable means. A portion of the end of each guide 46 and 48 is cut so as to form guide channels 50 and 52 in cooperation with the upper surface of the die block 30. The taped components 36 are fed through the guide channels 50 and 52 to the take up stage 16. It should be noted that the guides 46 and 48 may be adjusted so as to properly position the components 36 over the elongated aperture 54 of the die block 30.

The take-up stage 16 includes a pair of wheels 54 mounted on a common shaft 56. The shaft 56 is rotatably mounted to vertical 58 and 60. Shaft 56 extends through wall 60 and is connected by suitable gearing (not shown) to motor 62 and is driven thereby. The peripheral surfaces 55 of wheels 54 are knurled so as to engage the taped ends of the components 36. Wheels 64 are mounted to shaft 66 and are freely rotatable. Each wheel 64 is provided with an O-ring 68 to frictionally engage the upper surfaces of the taped ends of the components 36. The wheels 64 are held in frictional contact with the taped ends 38 by tension spring 70. In order to initially feed the taped ends 38 of the components 36 into the take-up reel or station 16, handle 72 is raised upward so as to move the wheels 64 away from the wheels 54. The taped ends 38 of the components may then be inserted in place and the wheels 64 brought back into the original position wherein the rings 68 will frictionally engage the taped edges 38. Spring 70 urges the respective wheels into engagement one with the other. Thus, when the motor 62 is energized. rotation of the wheels 54 will cause the taped ends 38 to be driven through the take-up station 16.

This results in the feeding of the components 36 from the supply reel 40. over the positioning rod 44 and through the cutting and forming station 14.

Referring now to FIGS. and 7, it is seen that the die block 30 is of an elongated shape. The die block 30 is formed with an elongated aperture or bore 54. The bore 54 extends through the block 30 in a tapered manner. Thus, the upper surface width is narrower than the bottom or lower surface width. The tapered bore facilitates in the automatic removal of the cut and formed components, as will be described hereinbelow.

The die block 30 is provided with a pair of elongated channels 74 on each side of the bore 54. Shoulders 76 separate the bore 54 from the channels 74 and provide a supporting surface for the leads 37 of the components 36, as best seen in FIG. 5.

The punch plate 28 is best seen in FIGS. 5 and 8 and is seen to be of an elongated shape of substantially equal length with that of the die block 30. The punch plate 28 is provided with a pair of downwardly projecting legs 78. Each of the legs 78 terminates in a cutting edge 80. The internal width between the legs 78 is such that the legs will travel along the interior edge of the channels 74 as the punch plate 28 is lowered in the position shown in FIG. 6. As the punch plate 28 is driven downwardly, the cutting edges 80 will engage the axial leads 37 and shear the same. Continued downward movement of the punch plate 28 will cause the severed leads 37 to be bent downwardly due to the beveled configuration of the end of the legs 78.

As particularly shown in FIG. 6, the punch plate 28 is formed with a central member 82 projecting downwardly therefrom. The member 82 is formed with a pair of shoulders 84 which project downwardly therefrom to define a component recess channel 86. The outermost corner 88 of each shoulder 84 is slightly rounded. It is seen that the vertical dimension of the member 82 and shoulders 84 is less than vertical dimension of the legs 78. Hence, during the downward movement of the punch plate 28 the leads 37 will be cut first by the cutting edge and the continued downward movement of the punch plate 28 will bring the shoulders 88 into contact with the leads 37. It may be noted that the external width of the shoulders 84 is substantially less than the width of the bore 54. As seen in FIG. 6, continued movement of the punch plate 28 downwardly will cause the leads 37 to be bent or formed upwardly along the external surface of the legs 84 and member 82.

The punch plate 28 will continue in the downward direction until the support plate 32 engages the punch plate stops 90. The force of the punch plate 28 in the downward direction imparts a downward momentum to the respective components 36 and leads 37 during the forming operation. At the point at which the punch plate 28 is stopped in its downward movement, the component 36 is at the position where the bore 54 begins the outward taper. Thus, the downward momentum of the component 36 is such that the components 36 will automatically fall through the bore 54 and a bore 35 in the support plate 35. A component tray 92 positioned below the support plate 34 collects the formed components 36.

It is seen that the punch plate 28 is of substantially the same length as the die block 30. Thus, a multiplicity of components 36 may be positioned along the upper surface of the die block 30 and this group of components will be cut, formed, ejected and collected in a sin gle downward motion of the punch plate 28.

As previously indicated, the downward motive force imparted to the punch plate 28 is derived from the punch press 20. Upon completion of the downwardly stroke, the punch plate 28 is retracted in a known manner until the support plate 32 engages a microswitch 94, as seen in FIGS. 3 and 5. Actuation of the microswitch 94 initiates a suitable timing circuit 96. The timing circuit 96 isolates the pneumatic and electrical circuitry of the press 20 so that the press 20 cannot be activated during the timing cycle. Simultaneously with the isolation of the press circuitry, the timing circuitry 96 activates the motor 62. Energization of the motor 62 drives the wheels 54 such that the scrap leads 39 (FIG. 4) are pulled through the take-up station 16. As the scrap leads which are still imbedded in the tape 38 are pulled or driven through the take-up station 16, a new group of components 36 are fed from the supply reel 40 and into position on the die block 30. At a preselected time interval, the timing circuitry 96 switches the motor 62 off and switches on the electrical and pneumatic circuitry of the punch press 20 such that another cycle of the punch plate 28 may occur.

Referring again to FIG. 1, it is seen that the apparatus 10 is provided with transparent plastic or safety glass or the like 98 about the periphery thereof. An aperture 100 is formed in one sheet of the plastic through which the nonformed components are fed through into cut and form station 14. A channel 102 is formed in the sheet at the opposite end so that the scrap leads and tape may be pulled from the cut and form station 14 to the take-up station 16.

The front sheet of plastic 98A is pivotally mounted to the support plate 22 by any suitable means such as by hinge 104. It is further seen that the plate 98A terminates just above the upper edge of the component tray 92. Thus, during operation of the apparatus the component tray 92 may be removed and a new tray inserted. Other than this operation, it is not possible for an operator to reach into the cut and form station during operation of the apparatus 10.

The plate 98A is secured in the closed position by any suitable means such as latch 106. It should be further noted that in the closed or operational position, the inside surface of the plate 98A engages a microswitch 108 which serves as a safety switch. The apparatus 10 will only operate when the safety switch 108 is engaged by the plate 98A. Thus, if the plate 98A is pivoted upwardly to an open position, the safety switch 108 cuts all power to the press such that the press cannot operate nor cycle. When the plate 98A is again closed, power is once again supplied to the press 20 and the apparatus 10 may then be operated. In operation, a supply of taped components 36 is mounted on the supply reel 40. The plate 98A is raised and the taped components 36 are fed through the aperture 100, across the cut and form station 14, Le, die block 30, and up to the take-up station 16. The plate 98A is closed and the apparatus 10 is energized by activation of the on-off switch 110. At this point, power from the press 20 is applied to drive the punch plate 28 downwardly to cut and form the group of components posi tioned upon the die block 30. At the end of the down ward stroke, the punch plate 28 retracted upwardly and the motor 62 is activated by the timing circuit 96. Motor 62 drives the respective take-up wheels such that a new group of components is brought into position on the die block 30 wherein the motor 62 is disengaged and the punch plate 28 is cycled once more.

lt is seen that the pre-former apparatus of this inven tion cuts and forms a plurality of components during a single operating cycle. Groups ofa plurality of the components to be cut and formed are sequentially moved into position upon the die block at the completion of each cycle of the punch plate. The scrap leads are removed from the cut and form station after each operational cycle and the components are ejected and collected in an easily accessible tray. Accordingly, it can be seen that the objectives hereinbefore set forth have been accomplished.

While a present exemplary embodiment of this invention has been illustrated and described, it will be recog nized that this invention may be otherwise variously embodied and practiced by those skilled in the art.

What is claimed is:

1. An electrical component pre-former for automatically cutting and forming groups of electrical components having axial leads supported at the ends of the leads by tape, the pre-former comprising:

a supply station having a supply of taped components therein;

a cut and form station including a die block and a complementally formed punch plate;

a take-up station, said taped components being initially manually fed from said supply station across said die block to said take-up station;

said take-up station including means for engaging the taped ends of said components;

motor means for rotatably driving said means wherein said taped ends are sequentially driven through said take-up station wherein groups of said components are moved across said die block;

timing means electrically connected with said motor to activate said motor to thereby drive said take-up station means after each group of components has been formed wherein a new group of components are brought into position relative to said die block;

power means for driving said punch plate into cooperative engagement with said die block thereby cutting and forming any components resting on said die block, said components having imparted thereto a momentum sufficient to travel through said die block, said punch plate being retracted at the completion of the cutting and forming step;

switch means being responsive to the retraction of said punch plate, said switch means being connected with said timing means wherein said motor means is actuated only when said punch plate is in the retracted position, said timing means permitting said motor to run for a predetermined time such that a new group of components are brought into position on said die block; and

means for collecting the cut and form components exiting from said die block.

2. The pre-former as set forth in claim 1 in which said die block is of an elongated shape, said block being formed with an elongated bore and extending there through, a pair of channels formed on either side of said bore wherein said component body is positioned in the bore area and the axial leads extend outwardly beyond said pair of channels.

3. The pre-former as set forth in claim 2 in which said punch plate is of an elongated shape and comprises a pair of downwardly projecting legs, said legs terminating in a cutting edge and being of a width such that each leg fits within a respective channel, a central member projecting downwardly and including a pair of downwardly projecting shoulders, said shoulders defining a component receiving channel therealong, said cutting edge of said legs projecting downwardly more than said shoulders wherein said cutting edge first cuts said axial leads in the downward stroke of said punch plate and continued downward movement of said punch plate brings said shoulders into contact with the axial leads positioned within said bore thereby urging said components and leads downwardly into said bore thereby forming said components positioned on said die block.

4. The pre-former as set forth in claim 3 in which the bore in said die block is formed with a downward and outward taper wherein the said formed components will fall through said tapered bore when said punch plate is retracted.

5. The pre-former as set forth in claim 4 further comprising a base upon which said die block is mounted;

a supporting plate vertically mounted above said base support, said punch plate being mounted for reciprocal vertical movement between said supporting plate and said die block;

transparent safety plates mounted between said support plate and base plate to enclose said cut and form station, the end plates being formed with apertures therethrough through which said tapered components can travel.

6. The pre-former as set forth in claim in which one said hinged plate is pivoted upward to disengage said transparent plate is pivotally Secured to the Support safety switch means whereby said punch plate cannot plate to permit access to the cut and form station, safety switch means responsive to said hinged plate wherein all power to said power means is cut off when 5 cycle when said hinged plate is in the open position.

UNITED STATES PATENT OFFICE CERTIFICATE OF CORRECTION PATENT NO. 3,872,898

DATED March 25, 1975 INVENTOR(S) William E. Parks it is certified that error appears in the above-identified patent and that said Letters Patent are hereby corrected as shown below:

Col. 3, line 14, "vertical 58 and 60" should read vertical walls 58 and 60 Col. 4, line 27, "plate 35" should read plate 34 Col. 4, line 38, "downwardly" should read downward Signed and sealed this 10th day of June 1975.

(SEAL) Attest:

C. MARSHALL DANN RUTH C. MASON Commissioner of Patents Attesting Officer and Trademarks 

1. An electrical component pre-former for automatically cutting and forming groups of electrical components having axial leads supported at the ends of the leads by tape, the pre-former comprising: a supply station having a supply of taped components therein; a cut and form station including a die block and a complementally formed punch plate; a take-up station, said taped components being initially manually fed from said supply station across said die block to said take-up station; said take-up station including means for engaging the taped ends of said components; motor means for rotatably driving said means wherein said taped ends are sequentially driven through said take-up station wherein groups of said components are moved across said die block; timing means electrically connected with said motor to activate said motor to thereby drive said take-up station means after each group of components has been formed wherein a new group of components are brought into position relative to said die block; power means for driving said punch plate into cooperative engagement with said die block thereby cutting and forming any components resting on said die block, said components having imparted thereto a momentum sufficient to travel through said die block, said punch plate being retracted at the completion of the cutting and forming step; switch means being responsive to the retraction of said punch plate, said switch means being connected with said timing means wherein said motor means is actuated only when said punch plate is in the retracted position, said timing means permitting said motor to run for a predetermined time such that a new group of components are brought into position on said die block; and means for collecting the cut and form components exiting from said die block.
 2. The pre-former as set forth in claim 1 in which said die block is of an elongated shape, said block being formed with an elongated bore and extending therethrough, a pair of channels formed on either side of said bore wherein said component body is positioned in the bore area and the axial leads extend outwardly beyond said pair of channels.
 3. The pre-former as set forth in claim 2 in which said punch plate is of an elongated shape and comprises a pair of downwardly projecting legs, said legs terminating in a cutting edge and being of a width such that each leg fits within a respective channel, a central member projecting downwardly and including a pair of downwardly projecting shoulders, said shoulders defining a component receiving channel therealong, said cutting Edge of said legs projecting downwardly more than said shoulders wherein said cutting edge first cuts said axial leads in the downward stroke of said punch plate and continued downward movement of said punch plate brings said shoulders into contact with the axial leads positioned within said bore thereby urging said components and leads downwardly into said bore thereby forming said components positioned on said die block.
 4. The pre-former as set forth in claim 3 in which the bore in said die block is formed with a downward and outward taper wherein the said formed components will fall through said tapered bore when said punch plate is retracted.
 5. The pre-former as set forth in claim 4 further comprising a base upon which said die block is mounted; a supporting plate vertically mounted above said base support, said punch plate being mounted for reciprocal vertical movement between said supporting plate and said die block; transparent safety plates mounted between said support plate and base plate to enclose said cut and form station, the end plates being formed with apertures therethrough through which said tapered components can travel.
 6. The pre-former as set forth in claim 5 in which one transparent plate is pivotally secured to the support plate to permit access to the cut and form station, safety switch means responsive to said hinged plate wherein all power to said power means is cut off when said hinged plate is pivoted upward to disengage said safety switch means whereby said punch plate cannot cycle when said hinged plate is in the open position. 